I am about to do the same repair on my truck. My thought was to flange the sunroof opening and cut a patch from my donor skin. Could also flange the patch if room is an issue.. On the inside I plan to use dyna mat in the old sunroof hole and add a headliner.. Thoughts??

I did that kind of repair on a 1966 chevelle that someone put a sunroof in. It worked great i drove the crap out of it and never had any problems. The car has been gone for a few years but i would like to think it held up well. Just take lots of time welding it in as u dont want to warp the thin sheetmetal.

Ok, so I finally got some time to finish the roof. I stripped and primed the inside of the roof, then installed the original insulation inside before buttoning it up. I ended up welding the front lip of the roof and using 3M panel adhesive on the back edge. I clamped it all together and let it sit over night. The results turned out great.